Recipe controlled device for making packaging materials

ABSTRACT

The present disclosure relates generally to an inflation and sealing machine and in particular to a method for modifying one or more parameters of the machine. The method includes identifying a configuration of a supply material to be used with the inflation and sealing machine, such as by receiving a user input, automatically detecting characteristics of the material, and/or receiving data such as from a sensor regarding the characteristics of the material. Once the configuration of the supply material is identified, the method includes receiving a selection of a prestored recipe according to a configuration of the supply material, where the recipe determines or sets the value for one or more operating parameters of the machine.

CROSS REFERENCE

This application claims the benefit of priority pursuant to 35 U.S. C.§119(e) to U.S. provisional application No. 61/944,026 filed Feb. 24,2015 entitled “Recipe Controlled Device for Making Packaging Materials,”which is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present disclosure is directed to devices and methods formanufacturing inflatable cushions to be used as packaging material.

BACKGROUND

A variety of inflated cushions are well-known and used for sundrypackaging applications. For example, inflated cushions are often used asvoid-fill packaging in a manner similar to or in place of foam peanuts,crumpled paper, and similar products. Also for example, inflatedcushions are often used as protective packaging in place of molded orextruded packaging components.

Generally, inflated cushions are formed from films having two layersthat are joined together by seals. The seals can be formedsimultaneously with inflation, so as to capture air therein, or prior toinflation to define a film configuration having inflatable chambers. Theinflatable chambers can be inflated with air or another gas orthereafter sealed to inhibit or prevent release of the air or gas.

Such film configurations can be stored in rolls or fan-folded boxes inwhich adjacent inflatable cushions are separated from each other byperforations. During use, a film configuration is inflated to formcushions and adjacent cushions or adjacent stands of cushions areseparated from each other along the perforations.

A variety of film configurations are currently available. Many of thesefilm configurations include seal configurations that tend to wastematerial, inhibit separation of adjacent inflated cushions, and/or forminflated cushions that are susceptible to under-inflation or leakage,thereby inhibiting utility.

The films are typically inflated by being pulled from a bulk quantity ofthe film and passed over or proximal to a nozzle. The nozzle blows airin between the films forming cushions. Heat is then used to bind twolayers of the film together forming a seal which limits air fromescaping. Frequently the films are poorly aligned or have too muchfreedom (e.g. slack) to be efficiently delivered to the nozzle forinflation. Additionally, due to the heat and pressures used in theprocess, the films may stick to machine surfaces or the film layers maybe pulled apart while still hot and exiting the mechanism.

SUMMARY

In one embodiment, the present disclosure relates generally to aninflation and sealing machine and in particular to a method formodifying one or more parameters of the machine. The method includesidentifying a configuration of a supply material to be used with theinflation and sealing machine, such as by receiving a user input,automatically detecting characteristics of the material, and/orreceiving data such as from a sensor regarding the characteristics ofthe material. Once the configuration of the supply material isidentified, the method includes receiving a selection of a prestoredrecipe according to a configuration of the supply material, where therecipe determines or sets the value for one or more operating parametersof the machine.

In another embodiment, the present disclosure relates generally to amethod for modifying one or more parameters of an inflation and sealingassembly. The method includes selecting a predetermined recipe from aplurality of recipes and configuring the inflation and sealing assemblyto operate based on the predetermined recipe. The predetermined recipeincludes settings for a plurality of components of the inflation andsealing assembly.

In yet another embodiment, the present disclosure generally relates to amethod for modifying one or more parameters of a machine. The methodincludes modifying a first parameter based on at least one of amaterial, a material size, a desired inflation rate, and inflationpocket geometry, or a feed speed, analyzing a second parameter todetermine if the second parameter is functionally related to the firstparameter, and if the second parameter is functionally related to thefirst parameter, adjusting the second parameter to correspond to themodification to the first parameter and if the second parameter if notfunctionally related to the first parameter, not adjusting the secondparameter.

In another embodiment, the present disclosure relates to a method forcreating packaging materials. The method includes selecting at least onematerial parameter of a packaging material, determining a setting for afirst machine parameter based on the at least one material parameter,adjusting the first machine parameter based on the setting, determiningif a second machine parameter should be adjusted based on the settingfor the first machine parameter, and adjusting the second machineparameter based on the determination.

In still another embodiment, the present disclosure relates to aninflation and sealing assembly. The assembly includes a spindle forreceiving a supply of material, a brake machine operably connected tothe spindle that selectively applies a frictional force to the supply ofmaterial, and a control system in communication with the brakemechanism, where the control system selectively varies the frictionalforce applied by the brake mechanism.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A-D are schematics of various embodiments of flexible structuresas used in conjunction with an inflation and sealing device;

FIG. 2 is perspective view of an inflation and sealing device inaccordance with various embodiments;

FIG. 3 is a perspective, exploded view thereof;

FIG. 4 is a top, right-side view as seen along axis Y of a materialsupport thereof;

FIG. 5 is a right-side view of a partially assembled system thereof;

FIG. 6 is a front view of the partially assembled device of FIG. 5;

FIG. 7 is a perspective, exploded view of a material support and brakeof the device of FIG. 2;

FIG. 8 is a right-side view of the material support and brake of thedevice of FIG. 2;

FIG. 9 is a right-side view of a sealing mechanism of the device of FIG.2;

FIG. 10 is a front, right perspective view thereof; and

FIG. 11 is a front, cross-sectional view of post-sealing controlelements taken along line XI-XI of FIG. 9.

FIG. 12 is a simplified block diagram of a control system for theinflation and sealing assembly.

FIG. 13 is a diagram of a display of the control system displaying iconscorresponding to one or more recipes for processing different supplymaterial configurations;

FIG. 14 is an elevation view of a roll of material for use with theinflation and sealing assembly including an identifier with theidentifier being sensed by a sensor of the control system.

FIG. 15 is a flow chart illustrating a method for modifying one or moremachine parameters based on one or more material parameters; and

FIG. 16 is a flow chart illustrating a method for modifying one or moremachine parameters based on modification of one machine parameter.

DETAILED DESCRIPTION

The present disclosure is related to systems and methods for convertinguninflated material into inflated cushions that may be used ascushioning or protection for packaging and shipping goods. In someembodiments, the systems may include a control system for determiningsettings for one or more parameters based on a desired material to beinflated, as well as the geometry of the inflated cushions, speed ofinflation, and other material parameters. The control system may also beconfigured to selectively modify the parameters of the packagingmachine, such as, but not limited to, adjusting a speed of one or moremotors (e.g., blower or drum motor), varying the temperature applied toa heating or sealing element, varying the fill rate or speed, as well ascontrolling the braking force applied to a roll brake. This allows thecontrol system to selectively modify the packaging machine based on thepackaging material and other material characteristics. In other words,the control system can adjust the machine to accommodate the materialconfiguration (i.e., the specific material characteristics of the film).Some examples of material characteristics include the particularmaterial, shape, cushion width, cushion length, cushion area, desiredcushion volume, desired fill level, and/or other characteristics of theinflatable cushions.

The control system may refer to one or more recipes storing settings fora plurality of machine parameters selected based on the desired supplypackaging material characteristics. For example, using a particular typeof material with inflatable cushions have a first geometry, the controlsystem can access a recipe specifying the speed of the drum roller, thetemperature of the heating element, the speed of the blower motor, andso on. The control system can then automatically adjust the parameterson the machine and/or provide instructions to a user to manually adjustthese parameters in some embodiments. Once the parameters are adjusted,the packaging system can be operated to create the desired packaging.

In some embodiments, the control system may analyze data to determinethe type of material and other material characteristics (e.g.,inflatable cushion geometries). For example, the roll of material mayinclude an identifier, such as a radio frequency identification (RFID)that designates the type of material, the gauge or thickness, thelength, the width, a perforation pattern, and/or pre-sealed pattern orother material features. The control system using one or more inputsensors, such as a RFID scanner, analyzes the roll to receive the RFID.Once the RFID has been received, the control system adjusts the machineparameters based on the data stored in the RFID. In some embodiments,the recipes may be stored on the machine items or on a computing devicein communication with the machine (e.g., via a network or WiFi).Alternatively or additionally, the RFID or other data on the roll mayinclude settings for each of the parameters. In other words, the rollsmay include the recipes or various settings for the machine parametersthat can be transmitted to the control system prior to operation.

The control system may also be configured to vary parameters of theinflation and sealing assembly based on the change or variation of otherparameters of the assembly. In some instances certain machine parametersmay be correlated to each other or otherwise related by one or morefunctions. As one example, the speed of a drum motor may be directlyrelated to the speed of the blower, the faster the drum motor spins asealing drum, the faster the blower motor may have be in order toadequately fill the inflatable cushions with the increased speed of thedrum. As another example, the speed of the drum may be related to thetemperature setting of the heating element. In this example, as the drumslows down, the temperature may need to be reduced since the materialmay move slower past the heating element. Other parameters includeparameters of the operation of the braking mechanism applied to the rollas it is unwound, such as the amount of braking friction or breakingtorque applied against the forward, unwind direction of the roll, and ofthe drive mechanism, such as the ramp up and ramp down profiles for thevarious motors of the inflation and sealing assembly, and so on.

Using the various interdependencies of the machine parameters, thecontrol system may automatically adjust or provide output to allow auser to adjust parameters based on the modification of other parameters.For example, if a user increases the speed of the drum motor, thecontrol system may automatically adjust the application of the brakingmechanism to slow the unwinding of the roll on the spindle or mayprovide output to alert a user to adjust the friction applied by thebraking mechanism. In this manner the control system can help avoiderrors or problems with the inflating and sealing assembly that couldresult from each of the parameters being adjusted improperly. Further,the control system may allow for more automation with the inflation andsealing assembly as the control system can determine the type ofmaterial loaded onto the spindle, adjust the assembly based on the typeof material, and then operate the assembly without a user being requiredto interact with the inflation and sealing assembly. The control systemmay also include one or more sensors for various components of themachine. This allows the control system to dynamically adjust theparameters based on the actual output of the parameter, as well asdynamically adjust other parameters that are dependent on the adjustedparameter. This helps to ensure that the inflation and sealing assemblyis running as desired, even as select parameters are adjusted.

In accordance with various embodiments, the various systems as discussedherein may be operable with any of a variety of mechanisms or systemsfor converting uninflated material into inflated flexible structuresthat may be used as cushioning or protection for packaging and shippinggoods. Specifically, mechanisms prior to sealing and inflation andmechanisms post-sealing and inflation may improve the overall efficiencyand speed of the process of forming the cushions. Prior to sealing andinflation, the system may include a material support element whichbetter stores, controls, and delivers the material to the sealing andinflation mechanisms. After the sealing and inflation of the material,material control elements may better direct the material out of thesystem without damaging the seal or failing to release the heatermaterial from the contact surfaces.

Illustrative embodiments and examples will now be described to providean overall understanding of the disclosed apparatus. Those of ordinaryskill in the art will understand that the disclosed apparatus can beadapted and modified to provide alternative embodiments of the apparatusfor other applications, and that other additions and modifications canbe made to the disclosed apparatus without departing from the scope ofthe present disclosure. For example, features of the illustrativeembodiments can be combined, separated, interchanged, and/or rearrangedto generate other embodiments. Such modifications and variations areintended to be included within the scope of the present disclosure.

Each of the embodiments, examples, aspects, representations, andillustrations of subject matter discussed herein may incorporate theembodiments, examples, aspects, representations, and illustrations asdisclosed, for example in U.S. application Ser. No. 13/844,741.Similarly, the subject matter discussed herein may also be incorporatedinto the various system disclosed in the incorporated references. Thevarious embodiments discussed herein or referenced herein are not meantto stand alone, but may be combined with other embodiments from theother referenced applications or various other embodiments disclosedherein. For example, the incorporated references variously describeinflation mechanisms (e.g. the variously structured nozzles, cuttingdevices, and air blowers) and sealing mechanisms (e.g. the variouslydisclosed sealing drums), each of which may be used herein as theinflation and sealing device utilized to process the web and form theresultant cushions.

FIGS. 1A-1D illustrates schematics of various embodiments of flexiblestructures. The flexible structure, such as a multi-layer web 100 offilm, for inflatable cushions is provided as an example of a filmstructure usable with the various systems discussed herein, withunderstanding that a person of ordinary skill in the art will recognizethe applicability of other film structures to the systems discussedherein. In various examples, the web includes a first film layer 105having a first longitudinal edge 102 and a second longitudinal edge 104,and a second film layer 107 having a first longitudinal edge 106 and asecond longitudinal edge 108. The second web layer 107 is aligned to beover lapping and can be generally coextensive with the first web layer105 (as shown in FIGS. 1A-1D), i.e., at least respective firstlongitudinal edges 102,106 are aligned with each other and/or secondlongitudinal edges 104,108 are aligned with each other. In someembodiments, the layers can be partially overlapping with inflatableareas in the region of overlap. The layers may be joined to define afirst longitudinal edge 110 and a second longitudinal edge 112 of thefilm 100. The first and second web layers 105,107 can be formed from asingle sheet of web material, a flattened tube of web material with oneedge slit, or two sheets of web material. For example, the first andsecond web layers 105,107 can include a single sheet of web materialthat is folded to define the joined second edges 104,108 (e.g., “c-foldfilm”). Alternatively, for example, the first and second web layers105,107 can include a tube of web material (e.g., a flatten tube) thatis slit along the aligned first longitudinal edges 102,106. Also, forexample, the first and second web layers 105,107 can include twoindependent sheets of web material joined, sealed, or otherwise attachedtogether along the aligned second edges 104, 108.

The web 100 can be formed from any of a variety of web materials knownto those of ordinary skill in the art. Such web materials include, butare not limited to, ethylene vinyl acetates (EVAs), metallocenes,polyethylene resins such as low density polyethylene (LDPE), linear lowdensity polyethylene (LLDPE), and high density polyethylene (HDPE), andblends thereof. Other materials and constructions can be used. Thedisclosed web 100 can be rolled on a hollow tube, a solid core, orfolded in a fan folded box, or in another desired form for storage andshipment.

As shown in FIGS. 1A-1D, the web 100 can include a series of transverseseals 118 disposed along the longitudinal extent of the web 100. Eachtransverse seal 118 extends from the longitudinal edge 112 towards theinflation channel 114, and in the embodiment shown, toward the firstlongitudinal edge 110. Each transverse seal 118 has a first end 122proximate the second longitudinal edge 112 and a second end 124 spaced atransverse dimension d from the first longitudinal edge 110 of the film110. A chamber 120 is defined within a boundary formed by thelongitudinal seal 112 and pair of adjacent transverse seals 118.

Each transverse seal 118 embodied in FIGS. 1A-1D is substantiallystraight and extends substantially perpendicular to the secondlongitudinal edge 112. It is appreciated, however, that otherarrangements of the transverse seals 118 are also possible. For example,in some embodiments, the transverse seals 118 have undulating or zigzagpatterns.

The transverse seals 118 as well as the sealed longitudinal edges110,112 can be formed from any of a variety of techniques known to thoseof ordinary skill in the art. Such techniques include, but are notlimited to, adhesion, friction, welding, fusion, heat sealing, lasersealing, and ultrasonic welding. An inflation region, such as a closedpassageway, which can be a longitudinal inflation channel 114, can beprovided. The longitudinal inflation channel 114, as shown in FIG. 1, isdisposed between the second end 124 of the transverse seals 118 and thefirst longitudinal edge 110 of the film. Preferably, the longitudinalinflation channel 114 extends longitudinally along the longitudinal side110 and an inflation opening 116 is disposed on at least one end of thelongitudinal inflation channel 114. The longitudinal inflation channel114 has a transverse width D. In the preferred embodiment, thetransverse width D is substantially the same distance as the transversedimension d between the longitudinal edge 110 and second ends 124. It isappreciated, however, that in other configurations other suitabletransverse width D sizes can be used.

The second longitudinal edge 112 and transverse seals 118 cooperativelydefine boundaries of inflatable chambers 120. In one preferredembodiment, the inflatable chambers 120 may further include intermediateseals 128. The intermediate seals 128 may seal the 105, 107 to oneanother at intermediate areas in the chamber 120. As shown in FIG. 1,opposing intermediate seals 128 are transversely aligned across thechamber 120. The intermediate seals 128 create bendable lines that allowfor a more flexible web 100 that can be easily bent or folded. Suchflexibility allows for the film 100 to wrap around regular and irregularshaped objects.

A series of lines of weaknesses 126 is disposed along the longitudinalextent of the film and extends transversely across the first and secondweb layers of the film 100. Each transverse line of weakness 126 extendsfrom the second longitudinal edge 112 and towards the first longitudinaledge 110. Each transverse lines of weakness 126 in the web 100 isdisposed between a pair of adjacent chambers 120. Preferably, each lineof weakness 126 is disposed between two adjacent transverse seals 118and between two adjacent chambers 120, as depicted in FIG. 1. Thetransverse lines of weakness 126 facilitate separation of adjacentinflatable cushions 120.

The transverse lines of weakness 126 can include a variety of lines ofweakness known by those of ordinary skill in the art. For example, insome embodiments, the transverse lines of weakness 126 include rows ofperforations, in which a row of perforations includes alternating landsand slits spaced along the transverse extent of the row. The lands andslits can occur at regular or irregular intervals along the transverseextent of the row. Alternatively, for example, in some embodiments, thetransverse lines of weakness 126 include score lines or the like formedin the web material.

The transverse lines of weakness 126 can be formed from a variety oftechniques known to those of ordinary skill in the art. Such techniquesinclude, but are not limited to, cutting (e.g., techniques that use acutting or toothed element, such as a bar, blade, block, roller, wheel,or the like) and/or scoring (e.g., techniques that reduce the strengthor thickness of material in the first and second web layers, such aselectro magnetic (e.g., laser) scoring and mechanical scoring).

Turning now to FIG. 2, an inflation and sealing device 101 forconverting a flexible structure such as web 100 of uninflated materialinto a series of inflated pillows or cushions 120 is provided as anexample of inflation and sealing devices that are usable with thevarious other systems discussed herein. As shown in FIG. 2, theuninflated web 100 can be a bulk quantity of supply, uninflatedmaterial. For example, the bulk quantity of uninflated material may be aroll of the material 134 as illustrated in FIGS. 2 and 3. The web 100may be rolled around an inner support tube 133.

The inflation and sealing device 101 may include a bulk material support136. The bulk quantity of uninflated material may be supported by thebulk material support 136. For example, the bulk material support may bea tray operable to hold the uninflated material, which tray can beprovided by a fixed surface or a plurality of rollers for example. Tohold a roll of material the tray may be concave around the roll or thetray may convex with the roll suspended over the tray. The bulk materialsupport may include multiple rollers which suspend the web. The bulkmaterial support may include a single roller that accommodates thecenter of the roll of web material 134. As illustrated in FIGS. 2-4, theroll of the material 134 may be suspended over the bulk material support136, such as a spindle passing through the core 133 of the roll of thematerial 134. Typically, the roll core is made of cardboard or othersuitable materials. The material support 136 may rotate about an axis Y.

The web 100 may be suspended over a guide 138 after being pulled off ofthe supply of uninflated material (e.g., roll 134). The guide mayprovide support to the web 100 upon a transition from the bulk quantityof uninflated material to the sealing and inflation mechanism 103discussed in more detail below. The guide may be a stationary rodextending from a support member 141. As shown in FIGS. 2-4, the guide138 may be a roller that which extends from the support member 141. Theguide 138 may have an axis X around which the guide 138 rotates. Theguide 138 or the axis X may extend generally perpendicularly from thesupport member 141. The guide 138 directs the web 100 away from the bulkquantity of uninflated material (e.g. roll 134) and steadily along amaterial path “B” along which the material is processed in alongitudinal direction “A”. As the bulk quantity of uninflated materialmay change position or dimension as the web 100 is continuously pulledfrom it (e.g. the roll 134 may decrease in diameter as material ispulled off), the guide may maintain alignment with the sealing andinflation mechanism despite these changes, and preferably with theupstream end of inflation tip 142. The guide 138 can be configured tolimit the material 134 from sagging between the inflation nozzle 140 androll 134, and can help maintain any desired tension in the web 100 ofthe material.

In accordance with various embodiments, the inflation and sealing device101 may include a support member 141. The support member 141 may includea base member 183 and a vertical member 186. The vertical member 186 maylocate the inflation and sealing assembly 103, guide 138, and materialsupport 136 relative to one another. The vertical member may be a flatwall. In various embodiments, the vertical member may have a verity ofshapes that may extend in various directions. The vertical member 186may be a single component which 103, 138 and 136 all attach to. In thismanner the various components the inflation and sealing assembly 103,guide 138, and material support 136 may have tolerances relative to oneanother based on the tolerances in the formation of the singlecomponent. This may very accurately locate the components relative toone another. Additionally the vertical member 186 and the base member183 may be a single component. For example, a bent piece of steel mayform the vertical member 186 the base member 183.

In accordance with various embodiments, the material support 136 mayextend from the support member 141 at an angle different than the anglefrom which guide 138 extends from the support member 141. As indicatedabove, guide 138 may extend from the support member 141 generallyperpendicularly, whereas the material support 136 may extend from thesupport member 141 non-perpendicularly. In other embodiments, neitherthe guide 138 nor the material support 136 may extend from the supportmember 141 perpendicularly.

FIG. 4 illustrates a view of the inflation and sealing device 101 alongaxis Y. As shown here, the material support 136 is shown on its end, butthe length of the guide 138 is shown in an isometric view illustratingan angular difference between the two. Notably here, the axis Y extendsup compared to axis X. FIG. 5 illustrates a front view showing the endof guide 138 but a bottom isometric view of material support 136. Again,the axis Y extends up compared to axis X. In accordance with variousembodiments, axes Y and X may be skew axes (i.e. the axes may be neitherparallel nor intersecting). The relative position of these axesindicates the relative position of the material support 136 and theguide 138. In accordance with embodiments discussed herein, the materialsupport 136 and the guide 138 may rotate around axes Y and Xrespectively. The axis X may be perpendicular to the support member 141with Y being non-perpendicular to the support member 141.

As illustrated in FIG. 6, axis Y or the material support 136 may bepositioned at an angle λ relative to the front wall 139 of the supportmember 141. The angle λ may be greater than 90°. For example, λ may be70° to 140°. In one example, λ may be about 100°. However, the materialsupport 136 and the guide 138 may be attached to different surfaces orat different angles, such as both pointed upwards with respect to thefront wall 139 or both pointed down words with respect to the frontwall. As viewed from the side (e.g. FIG. 6), the angle between axis Xand axis Y may be Θ. Θ may be an angle between the axes that ranges fromabout 5° to about 70°. Θ may be an angle between the axes that rangesfrom about 10° to about 45°. In accordance with various embodiments, theweb 100 may travel through the inflation and sealing device 101 alongpath E. As illustrated in FIGS. 3 and 4, the film path E extends alongthe nozzle 140. An axis Z is located where the film path E follows thenozzle 140. In accordance with various embodiments, the direction thatnozzle 140 points is the same direction axis Y points. For example ifnozzle 140 points up (e.g. away from base 183) then axis Y points up. Ifnozzle 140 points down (e.g. toward base 183) then axis Y points down.

In various embodiments, the web 100 may pass above the guide 138. Insuch embodiments, the material support 136 and axis Y may be angled withrespect to guide 138 such that the material support 136 and axis Y pointin the same direction as the web 100 passes over guide 138. If web 100passes over guide 138 then the material support 136 may point uprelative to the guide 138. If web 100 passes under then guide 138, thenthe material support 136 may point down relative to guide 138.

In accordance with various embodiments, the web 100 passes through theinflation and sealing assembly 103 and extends away from the inflationand sealing device 101 in a transverse direction which is perpendicularto longitudinal direction A in which the web 100 exits the inflation andsealing device 101. An axis W may be aligned at the pinch area 176 andextend in the transverse direction away from the inflation and sealingdevice 101. The angle ω between the axis W and the axis Y may be anangle between the ranges from about 5° to about 70°. The angle ω betweenW and the axis Y may be an angle between about 10° to about 45°. Theangle may be viewed in the longitudinal direction such as from the frontof the inflation and sealing device 101 such as shown in FIG. 6.

In some embodiments axes Y and X may be parallel, for example bothextending though the support member 141 perpendicularly, both may extenddownwardly, or both may extend upwardly. As indicated above Y and X maybe non-parallel with both extending downwardly, or both extendingupwardly.

When the web 100 is removed from the material support 136 and ispositioned at an angle different from the guide 138, the web 100includes a slight twist as it is removed from the bulk quantity ofuninflated material (e.g. roll 134) and re-aligned over and in contactwith guide 138. The web 100 may roll off of material support 136tangentially and thereby forming a plane (or a surface that approximatesa plane tangential with the surface of the roll 134) that is parallelwith the axis of material support 136. The web 100 may also engage guide138 tangentially forming a different plane (or approximating a differentplane tangent with the guide 138). The web may merely reflect tangentialplanes as if it maintained tangential contact with the material support136 or guide 138 even if in practice there is tension on one transverseend of the web 100 and slack on the other transvers end of the web 100.In order to accommodate both tangential contacts the web 100 may realignor twist slightly between the material support 136 and guide 138. Thisrealignment of the web 100 may cause this slight twist which may affectthe way that the web 100 contacts guide 138. In embodiments whereinangle λ is greater than 90 degrees, the slight twist causes the web 100to have greater pressure against the guide 138 proximate to theconnection between guide 138 and the support member 141. The web 100 mayhave lesser pressure and less tension on the end of guide 138 that isdistal to the connection between guide 138 and the support member 141.This configuration of contact between web 100 and guide 138 aids inmaintaining alignment of the web toward the sealing mechanism andlimiting the tendency of the web 100 to drift off the end of guide 138that is distal of the support member 141. On a related note, the end ofthe material support 136 can have a tendency to sag underweight, such asunder the weight of a roll of material 134 being mounted thereon. Assuch, in response to the material support 136 being structured extendingperpendicularly from the support member 141, the material support 136and or axis Y tends to deflect downwardly when the roll of material 134is mounted thereon. In this position the opposite effect to the onediscussed above occurs. The web 100 may contact the guide 138 withgreater pressure on the end of the guide 138 that is distal to thesupport member 141. Conversely, the side of the guide 138 that isproximate to the support member 141 may have less pressure between theguide 138 and the web 100 as compared to the distal end of guide 138. Inthis way, web 100 may tend to drift off the guide 138, become un-alignedwith the sealing and inflation mechanism, or acquire slack between theroll of material 134 and the sealing and inflation mechanism. Thus, bystructuring the material support 136 with an angle greater than theguide 138 as measured upwardly from the support member 141 (e.g. seeFIG. 6) the sag in the material support 136 and the tension issues withthe guide 138 may be overcome, thereby improving the intake of web 100into the sealing and inflation mechanism.

In accordance with various embodiments, the nozzle 140 may inflate web100 not only at a transverse edge but may engage an inflation channellocated at any transverse distance between the longitudinal edges; i.e.,the inflation and sealing device 101 fills a central channel withchambers on both transverse sides of the inflation channel. The web 100may roll off of material support 136 and over guide 138 in a manner thataligns such a central inflation channel with the nozzle 140.

As discussed above, in various embodiments the material support 136 mayinclude a spindle 200. The spindle 200 may be axially aligned along axisY with a motor 220. The motor 220 and the spindle 200 may be attachedvia a bulkhead connector 222. The bulk head connector 222 may have amounting surface 223. The mounting surface may attach to the backside ofthe support member 141 such that the motor 220 may be positioned on oneside and the spindle 200 may be positioned on the other side asillustrated in FIG. 6. The mounting surface 223 may form an angle withaxis Y such that axis Y is not perpendicular thereto. For example, FIG.6 shows mounting surface 223 as parallel with vertical plate 184. Assuch, λ represents the angle between mounting surface 223 and Y.Instead, the mounting surface 223 may be angled such that as it attachesto the back side of the support member 141, it tilts the spindle 200 andmotor 220 relative to the support member 141. An example of thisstructure is shown in FIG. 6 with the angle λ which may also representthe angle between mounting surface 223 and the axis Y. Spindle 200 maybe supported within the bulk head connector 222 by bearings 214 and 224.The bearings 214,224 may allow the spindle 200 to be rotatableindependent of the bulkhead connector 222 and ultimately the supportmember 141, to which the bulkhead connector 222 attaches. In variousembodiments, the spindle may be supported on a shaft, surface bearings,or by the motor directly. The spindle 200 may be locked into place onthe bulk head 222 with clip 226. Cover 228 and bulk head connector 222may form an enclosure around motor 220.

The spindle 200 may include two sections, a body portion 202 and a tipportion 204. The body portion 202 and the tip portion 204 may be formedof different materials. 6. The spindle 200 preferably has core supportportions 206, which are spaced circumferentially about axis Y from eachother to provide radially recessed areas 208 therebetween. The coresupport portions 206 protrude radially from the axis Y higher than thesurfaces of the spindle 200 in the radially recessed areas 208. The coresupport portions can collectively define and be positioned along aphantom cylindrical surface that will correspond closely to theinterior, hollow, surface within a supply roll 134. If other shapedcores are to be used, the core support portions can be arranged in othershapes. The core support portions 206 can be curved circumferentiallyalong this phantom cylindrical surface or can be flat or have othershapes. The recessed areas 208 are positioned radially inward of thephantom cylinder, so that they entirely or in large part do not contactthe interior of a supply roll mounted on the spindle 200. The recessedareas 208 have substantially flat surfaces in the embodiment shown, butother configurations can be used.

In the embodiment of FIG. 7, the recessed areas 208 lie below thephantom cylinder 207, and the core support portions 206 generally followthe phantom cylinder 207, although other shapes can be used. In thismanner, the spindle 200 may be generally triangular in shape havingthree core support portions 206, but can alternatively have four, five,or more core support surfaces, and the core support portions can beevenly or unevenly distributed circumferentially about the spindle. Thecore support surfaces 206 preferably extend substantially axially withrespect to the spindle (transversely with respect to the material pathor machine direction in the embodiment of FIG. 2) to help in sliding aweb roll core 133 on and off the spindle.

By providing the recessed areas between the core support portions 206provides the spindle with a discontinuous support surface in which thecontact area it has with a core 133 of a supply web roll 134 can bereduced compared to traditional, continuous-surface cylindricalspindles. This reduces the friction between the spindle 200 and core133, allowing the core 133 to be more easily inserted and slid off fromthe spindle 200. Additionally, as is common and can be seen in FIG. 4,the core 133 can be deformed, such as by damage during shipping of thesupply material roll 134. Damaged, out-of-round cores can be verydifficult or impossible to insert onto a fully cylindrical spindle. Therecessed areas 208 on the discontinuous spindle surface can accommodatedeformations of the core 133 that extend inwardly between the coresupport portions 206, allowing dented or flattened cores to remainuseable. In this way, the core support surfaces 206 a,b,c or a pluralityof grip elements 210 which extend from the core support surfaces 206a,b,c, may contacts or occupy only a fraction of the outer core surfacecircumference. The plurality of contacts may contact a finite number ofpoints within an internal surface of a hollow tube onto which the web ofmaterial is rolled. In various examples, the plurality of grip elements210 may extend beyond the generally cylindrical shape shown by line 207.The plurality of contacts may form a larger diameter around the spindlethan the size of the inner diameter of inner support tube 133. Thisstructure would allow the plurality of contacts to engage in aninterference fit with the core 133 while the minimized outer cylindricalsurface segments 206 a,b,c minimize other contact within the core 133.Preferably, the grip elements 210 are biased outwardly and areresiliently movable inwardly into the spindle 200. Such bias can beprovided by springs within the spindle. The outer surface of the gripelements 210 can be spherical, conical, or have another shape thatpreferably facilitates sliding of the core 133 during loading andunloading on or from the spindle, and that grips the inner surface ofthe core 133 during use, to help transfer torque from the spindle to theroll, and preferably from the brake 137, described below. A chamfer 204at the end of tip portion 204 may additionally reduce the effort ofinserting spindle 200 into the inner support tube 133.

Referring back to FIGS. 2-6, the support element 136 may be connectedwith a brake 137. The brake 137 may prevent or inhibit bunching up ofthe web material 100 and maintain a desired tension in the web material100 as it is unwound from the roll 134 and as it is fed onto and/or intothe inflation and sealing mechanism. The brake 137 may prevent orinhibit release of the bulk uninflated material from the support 136.For example, the brake 137 may inhibit the free unwinding of the roll134. The brake may also assure that the roll 134 is unwound at a steadyand controlled rate. The brake 137 may be provided by any mechanism thatprovides control. For example, according to one embodiment, aspring-loaded leather strap or other friction mechanism can be used as adrag brake on the bulk material support 136. In another embodiment, thebrake 134 may be an electric motor or other actuator used to provideresistance to the rotation of the bulk material support 136 as the roll134 is unwound. As shown in FIGS. 7-8, the support element 136 isspindle 200 which is axially connected to a brake which may operate as aresistance mechanism. The resistance mechanism resists rotation of thesupport element 136 (e.g. spindle 200). The resistance mechanism may bemotor 220 which controls rotation of the spindle 200, therebycontrolling advancement of the web 100 by either positively drivingrotation of spindle 200 or retarding the rotation of spindle 200. Byretarding the rotation of spindle 200, the brake can also increasetension on the twisted web proximal to the support member 141,maintaining proper alignment with the inflating/sealing mechanism.

Preferably, the inflation and sealing device 101 is configured forcontinuous inflation of the web 100 as it is unraveled from the roll134. The roll 134, preferably, comprises a plurality of chain ofchambers 120 that are arranged in series. To begin manufacturing theinflated pillows from the web material 100, the inflation opening 116 ofthe web 100 is inserted around an inflation assembly, such as aninflation nozzle 140. In the embodiment shown in FIG. 2, preferably, theweb 100 is advanced over the inflation nozzle 140 with the chambers 120extending transversely with respect to the inflation nozzle 140 andoutlet 146. The outlet 146, which can be disposed on a radial sideand/or the upstream tip of the nozzle 140, for example, directs fluidfrom nozzle body 144 into the chambers 120 to inflate the chambers 120as the web 100 advances along the material path “E” in a longitudinaldirection “A”. The inflated web 100 is then sealed by a sealing drum 166in the sealing area 174 to form a chain of inflated pillows or cushions.

The side inflation area 168 in the embodiment of FIG. 3 is shown as theportion of the inflation and sealing device 101 along the path “E”adjacent the side outlets 146 in which air from the side outlets 146 caninflate the chambers 120. In some embodiments, the inflation area 168 isthe area disposed between the inflation tip 142 and entry pinch area176, described below. The web 100 is inserted around the inflationnozzle 140 at the inflation tip 142, which may be disposed at theforward-most end of the inflation nozzle 140. The inflation nozzle 140inserts fluid, such as pressured air, along fluid path B into theuninflated web material through nozzle outlets, inflating the materialinto inflated pillows or cushions 120. The inflation nozzle 140 caninclude a nozzle inflation channel that fluidly connects a fluid sourcewith the nozzle outlets. It is appreciated that in other configurations,the fluid can be other suitable pressured gas, foam, or liquid. FIGS. 3,9, 10, and 11 illustrates a various view of the inflation and sealingdevice 101. As discussed in various embodiments, the fluid source can bedisposed behind the support member 141 having a horizontal plate 183 andvertical plate 184 or other structural support for the nozzle andsealing assemblies, and preferably behind the inflation nozzle 140. Thefluid source is connected to and feeds the fluid inflation nozzleconduit 143. The web 100 is fed over the inflation nozzle 140, whichdirects the web to the inflation and sealing assembly 103. The web 100is advanced or driven through the inflation and sealing device 101 by adrive mechanism, such as by a driver or sealing drum 166 or the driveroller 160, in a downstream direction along a material path “E”.

In accordance with various embodiments, the nozzle, blower sealingassembly, and drive mechanisms, and their various components or relatedsystems may be structured, positioned, and operated as disclosed in anyof the various embodiments described in the incorporated references suchas for example U.S. patent application Ser. No. 13/844,741. Each ofthese embodiments may be incorporated to the inflation and sealingdevice 101 as discussed herein.

After being fed through the web feed area 164, the first and second weblayers 105,107 are sealed together by the sealing assembly and exit thesealing drum 166. The sealing drum 166 includes heating elements, suchas thermocouples, which melt, fuse, join, bind, or unite together thetwo web layers 105,107, or other types of welding or sealing elements.The web 100 is continuously advanced through the sealing assembly alongthe material path “E” and past the sealing drum 166 at a sealing area174 to form a continuous longitudinal seal 170 along the web by sealingthe first and second web layers 105,107 together, and exits the sealingarea at an exit pinch area 178. The exit pinch area 178 is the areadisposed downstream the entry pinch area 164 between the belt 162 andthe sealing drum 166, as shown in FIG. 4. The sealing area 174 is thearea between the entry pinch area 164 and exit pinch area 178 in whichthe web 100 is being sealed by the sealing drum 166. The longitudinalseal 170 is shown as the phantom line in FIG. 1. Preferably, thelongitudinal seal 170 is disposed a transverse distance from the firstlongitudinal edge 102,106, and, most preferably, the longitudinal seal170 is disposed along the mouths 125 of each of the chambers 120.

Preferably, as shown in FIG. 4, the sealing drum 166 is arranged abovethe belt 162. The drive roller 160 is preferably positioned downstreamthe feed roller 158 and tension roller 156 with the sealing drum 166there between. The sealing drum 166 is disposed such that a portion ofthe sealing drum 166 vertically overlaps the feed roller 158, tensionroller 156, and drive roller 160 so that the belt 162 is deformed at thesealing area 174 to have a generally U-configuration. Such configurationincreases the tension of the belt 162 at the sealing area 174, andfacilitates the pinching of the web 100 between the sealing drum 166 andthe belt 162 at the sealing area 174. The inflation and sealing assembly103 configuration described also reduces the amount of contact of theweb 100 during sealing, which reduces bending of the inflated web. Asshown in FIG. 7, the contact area is the sealing area 174 between theentering pinch area 164 and exiting pinch area 174.

In the embodiment shown, the web 100 enters the sealing assembly at theentry pinch area 176 at an angle sloping downward with respect to thehorizontal. Additionally, the web 100 exits the sealing area 174 at anangle sloping upward with the respect to the horizontal so that the web100 is exiting facing upwards toward the user. By having the intake andouttake sloped as described herein, the inflation and sealing device 101allows for easy loading and extracting of the web as well as easy accessto the web. Thus, the inflation and sealing device 101 can be positionedbelow eye level, such as on a table top, without the need of a highstand. The sloping downward intake and sloping upward outtake of the web100 from the sealing assembly provides for the material path “E” to bebent at an angle α between the entry pinch area 176 and the exit pincharea 174 (the entry pinch area 176 and exit pinch area 174 are furtherdescribed below). The angle α between the entry pinch area 176 and exitpinch area 174 is, for example, at least about 40 degrees up to at mostabout 180 degrees. The angle α may be about 90 degrees. Other entry andexit angles can be employed as known in the art in alternativeembodiments.

In accordance with various embodiments, the sealing assembly may beprotected by a removable cover. Likewise, the belt mechanism, e.g. belt162, tension roller 156, and feed roller 158 may also include aremovable cover 173. This allows for a user to easily remove the web orclear up or fix jams within the machine.

In accordance with various embodiments, one or more of the elements ofinflation and sealing device 101 may drive web 100 through the system.For example, the sealing drum 166 may be connected to a motor whichrotates it in a direction “F”. As described in various embodiments (seee.g. application Ser. No. 13/844,741), other elements may also drive thesystem, such as roller 160. In other embodiments discussed in theincorporated references, roller 160 is indicated as a drive roller;however, it may be noted that roller 160 may be either an idler rolleror an active drive roller. For example, roller 160 may be connected tothe same motor or the same drive mechanism associated with the sealerdrum 166 that causes the drum to rotate. In other configurations, thesealing drum 166 may be passive (e.g. an idler) or actively driven by amotor. In one example, the sealing drum 166 may be passive and merely berotated in response to the advancing web 100 or belt 162.

In accordance with various embodiments, the inflation and sealing devicecan have more than one belt. For example one belt may drive the variousrollers and a second belt may pinch the web against the sealing drum. Invarious embodiments, the inflation and sealing device may have no belts.For example the sealing drum may pinch the web against a stationaryplatform and drive the web thorough the inflation and sealing device atthe same time. Additional description and embodiments of such structuresmay be disclosed in U.S. Pat. Nos. 8,061,110 and 8,128,770 andPublication No. 2011/0172072 each of which is herein incorporated byreference.

Although some embodiments do not have a post-seal control element, theinflation and sealing assembly 103 shown in FIG. 2 includes a pluralityof post-seal control elements. In various embodiments, the post-sealcontrol element may be a movable or stationary surface, a roller, or anydevice that can contact the belt 162 or the web 100. For example, apost-seal control element can include roller 160 as discussed above. Theroller 160 supports the web 100 exiting from the inflation and sealingassembly 103 and may be operable to guide the belt. As illustrated inFIGS. 9-11, the roller 172 may also be a post-seal control element. Invarious embodiments, there may be a single post-seal control elementsuch as roller 160 as depicted in embodiments disclosed in theincorporated references (see e.g. Ser. No. 13/844,741). In otherembodiments, there may be multiple post-seal control elements asillustrated in FIGS. 9-11. For example, a first post-seal controlelement (e.g. roller 172) can be disposed directly above a secondpost-seal control element (e.g. roller 160).

The two post-seal control elements (e.g. two rollers 160,172) pinch orpress the web 100 so that the belt 162 abuts one or both of the surfacesof the elements. As the rollers 160,173 are disposed immediatelydownstream of the heating drum (or other heating mechanism in otherembodiments), they provide a cooling region 179 disposed between tworollers 160,172. Roller 160 in this embodiment acts as a principlecooling roller, since the sealed and cooling film is drawn around thisroller 160. Pinch roller 172 maintains the web in contact with theprinciple cooling roller 160 to help maintain the pressure between thetwo film layers as the seal cools to support the seal and surroundingarea mechanically. In embodiments, such as the one shown, in which thebelt 162 extends around roller 160, the outer surface of this rollerremain substantially stationary with respect to the web 100, furtherhelping support the seal in its delicate state before it has cooledsufficiently. Roller 160 is typically made of a hard and tough material,such as steel or aluminum, to withstand the pressures and heat from thebelt 162, although a plastic or other material could be used in someembodiments.

In various embodiments, the post-seal control element such as roller 172may have a larger-diameter area 171 opposing the belt than in adjacentparts of pinch roller 172. This annular ridge 171 allows contact againstthe web 100, while an adjacent smaller-diameter portion of roller 172can remain out of contact therewith to help prevent sticking to the hotweb. The roller 172 may be biased against the belt 162, web 100, androller 160 by a spring-loaded tensioner 169. The tension provided by thetensioner 169 may further hold the seal closed by the post-seal controlelement, and can allow the pinch roller 172 to be lifted off the webwhen needed. To prevent or reduce sticking of the hot web 100 to thepinch roller 172, the pinch roller is preferably made of, or has asurface of, a non-stick or low adhesion material such aspolytetrafluoroethylene (PTFE) or other suitable material. In accordancewith various embodiments, the post-seal control element such as roller160 may include a recessed annular surface 163. The recessed annularsurface 163 may receive the belt 162.

When the web exits pinch area 178 between rollers 160 and 172, there isa possibility that the hot film will stick to one of these rollersinstead of cleanly exiting the device. In various embodiments, anelement can be provided to help separate the film from the post-sealcontrol elements. For example, roller 172 can have an annular ridge 161extending proud the belt 162 or outer surface 167 of the roller 160 thatsupports the belt 162 against the web 100, or that contacts the web 100.This ridge 161 can be annular or have another suitable shape and can runaround the roller to contact the web 100, preferably transverselyadjacent the longitudinal seal on the inflated web 100, such as againstthe transverse end of the inflated chambers 120 adjacent thelongitudinal seal 112. At the pinch area 178, the annular ridge 161contacts the web 100, typically against a transverse side of theinflated chambers 120 where due to the inflated shape, the chambers 120have a degree of rigidity compared to the uninflated film. The elevatedridge provides a bump-off element that forcing the web 100 to deflectoff the roller 160. This deflection may cause the web 100 to unseat, andoften unstick, from the belt and/or the roller 160. As such, the annularridge 161 aids in automatically peeling the web 100 off the post-sealcontrol elements. While described with respect to a roller, alternativeembodiments can have a stationary ridge provided adjacent the roller 160to guide the web off the cylinder.

As the heated web 100 may have a tendency to stick to the post-sealcontrol elements, non-stick materials may mitigate this issue. Forexample, one or both post-seal control elements may be made from ofcoated with polytetrafluoroethylene (PTFE), anodized aluminum, ceramic,silicone, or like non-stick/low-adhesion materials.

In the embodiment shown, the inflation and sealing device 101 furtherincludes a cutting assembly 186 to cut the web off the inflation nozzlewhen an inflation channel that receives and is closed around alongitudinal inflation nozzle 140 is used. As with other systemcomponents discussed herein, the cutting assembly may also bestructured, provided, or included in accordance with the variousembodiments described by the incorporated references discussed above.

Control System and Recipes for the Inflation and Sealing Assembly

As explained above various inflation and sealing assembly (such as thosediscussed above or similar to those discussed above) may include acontrol system that can save or otherwise access recipes thatautomatically set parameters of the machine to create packaging materialbased on the uninflated materials loaded into the machine. Withreference to FIG. 12, the control system 1000 of the inflation andsealing assembly will now be discussed in more detail. The controlsystem 1000 may include one or more processing elements 1002, a display1004, one or more memory components 1006, an input/output interface1012, one or more sensors 1016, and a power source 1014. Each of thecomponents of the control system 1000 may be in communication with othercomponents via one or more system buses or other communication means.Additionally, the control system 1000 may include and/or be incommunication with the blower motor 1013, the brake mechanism 137, theheating element 177, and other components of the inflation and sealingassembly that may be tracked and/or modified by the control system 1000.

The processor 1002 or processing element 1002 may control one or morefunctions and/or operations of the control system 1000 and/or inflationand sealing assembly. The processing element 1002 may be incommunication, either directly or indirectly, with substantially all ofthe components of the control system 1000. The processing element 1002may be any type electronic device capable of processing, receiving,and/or transmitting instructions. For example, the processing element1002 may be a microprocessor or a microcomputer. As described herein,the terms “processor” and “processor element” are meant to encompass asingle processor or processing unit, multiple processors, or multipleprocessing units, or other suitably configured computing element.

The memory component 1006 may include one or more storage or memorycomponents that store electronic data that may be utilized by thecontrol system 1000 and/or inflation and sealing assembly. For example,the memory 1006 can store electrical data or content, e.g., recipes orsettings for the inflation and sealing assembly for select materials,document files, audio files, and so on. The memory 1006 may be, forexample, magneto-optical storage medium, read only medium, random accessmemory, erasable programmable memory, or flash memory.

The input/output interface 1012 receives and transmits data and providesconnection to one or more components. For example, the input/outputinterface 1012 may receive user input through one or more input devices(e.g., keyboard, mouse, touch screen, or the like), and may transmitdata between the control system 1000 and other electronic devices (e.g.,computers, other control systems, or the like). Additionally, theinput/output interface 1012 may facilitate output to one or more outputdevices, such as the display 1004, speakers, headphones, or the like.The input/output interface 1012 may transmit and receive data in avarious manners across one or more networks (e.g., WiFi, Ethernet,Bluetooth), cellular networks, and so on. The type of communicationnetwork may depend on a variety of different requirements, designparameters, and so on, and as such the input/output interface 1012 maybe modified as desired.

The power source 1014 may be substantially any device capable ofproviding energy to the various components of the inflation and sealingassembly as well as the control system 1000. For example, the powersource 1014 may be a connection cable configured to connect the assemblyto another power source, such as a wall outlet, and/or the power source1014 may be a battery or other portable energy storage component.

The display 1004 provides a visual output for the control system 1000.In many embodiments the display 1004 may be used to provide output to auser by displaying data, images, video, or the like. Additionally, thedisplay 1004 may cooperate with the input/output interface 1012 toreceive data input. For example, the display 1004 may include one ormore touch sensors that receive inputs from a user (e.g., capacitive orresistive touch screen). The display 1004 may be substantially any typeof visual output device, such as, but not limited to, liquid crystaldisplay (LCD), light emitting diode (LED) display, plasma display, orthe like. The type and size of the display 1004 may depend on the typeof inflation and sealing assembly as well as the control system 1000.

The one or more sensors 1016 are sensing elements that can sense changesin one or more characteristics or parameters. For example, the sensors1016 may include a temperature sensor, an image sensor (e.g., camera), aspeed or motion sensor, rotation sensor, accelerometer, gyroscope, orthe like. The sensors 1016 are configured to detect informationcorresponding to one or more components of the inflation and sealingassembly, information about the material loaded onto the spindle 136 ofthe inflation and sealing assembly (e.g., one or more of the materialcharacteristics), and/or data about other assemblies or control system1000. Accordingly, the sensors 1016 may be positioned at variouslocations of the inflation and sealing providing the sensors 1016 withsufficient access to or communication with the monitored component todetect its settings and/or operating parameters. As an example, theheating element 177 may include a temperature sensor operably connectedthereto where the temperature sensor can detect the current temperatureof the heating element.

In embodiments including sensors 1016 to detect information about thematerial used with the inflation and sealing assembly, the sensors 1016may be used to analyze the material itself, one or more identifiers onthe material, and/or the like. For example, the sensors 1016 may includea barcode scanner that can read a barcode imprinted on the material orpackaging of the material. As another example, the sensors 1016 mayinclude a RFID receiver/transmitter that receives data corresponding toa RFID tag or other identifier. As yet another example, the sensors 1016may include a material sensor that can determine the type, width,thickness, or the other features of the material to be used with theinflation and sealing assembly. The types of sensors 1016, as well astheir locations, may be modified as desired and based on the type ofassembly, control system 1000, and/or material.

The sensors 1016 may be configured to read data corresponding to thematerial and/or machine parameters directly from the material. FIG. 14is a diagram illustrating a roll of material 1009 including anidentifier 1010. With reference to FIG. 14, the sensor 1016 ispositioned to be in communication (e.g., optical and/or electrical) withthe material roll 1009. This allows the control system 1000 to determinethe type of material, the amount of material left on the roll, one ormore recipes associated with the material, or one or more machineparameters for the material, by sensing the identifier 1010 using thesensor 1016. As a first example, the sensor 1016 may be a RFID readerand the identifier 1010 may be a RFID tag. As a second example, sensor1016 may be a barcode reader or quick response (QR) code reader and theidentifier 1010 may be a barcode or QR code. As a third example, theidentifier 1010 may be a printed or text recipe including a listing ofmachine parameters (e.g., sealing temperature, inflationcharacteristics, etc.) and the sensor 1016 may be a camera that capturesthe recipe and using a text recognizer function to input the recipe intothe control system 1000.

An example of using the display 1004 to receive input to the controlsystem 1000 will now be discussed. FIG. 13 is a front elevation view ofan illustrative display for the control system. With reference to FIG.13, the display 1004 includes an output of one or more icons 1020, 1022,1024. Each of the icons 1020, 1022, 1024 may correspond to a material,such as an arbitrary name of the material (e.g., trade name), a materialtype or characteristics (e.g., 10 mm, polyethylene), a recipe name(which may be set to be similar to the trade name or name of thematerial) or other material identifier. The control system 1000 mayreceive a user input indicating the type of material that is loaded ontothe inflation and sealing assembly or a material that is to be used withthe inflation and sealing assembly. As one example, the user may selectone of the icons 1020, 1022, 1024 corresponding to the material that isto be used by using his or her finger or by using an input device (e.g.,stylus, capacitive touch screen, mouse, keyboard, etc.). As anotherexample, the user may directly input the recipe name into the controlsystem. In some embodiments, the control system 1000 may require apassword, user identification, or other security feature before a recipecan be selected or before any parameters can be manually orautomatically adjusted. In some embodiments, the icons and/or the recipenames may correspond to the material or the material characteristics,e.g., the recipe name may be similar to the trade name of the materialor the recipe may

In this example, the processor 1002 may access recipes stored in thememory component 1006 corresponding to each of the available materials.In other words, the memory component 1006 may store parameter settingsfor each of the components for the inflation and sealing assembly thatare to be used when the select material is being inflated and sealedwith the assembly. In this manner, the control system 1000 canautomatically adjust the inflation and sealing assembly based on thematerial. FIGS. 1A-1D illustrate top plan views of examples of materialsincluding different inflating configurations. Each of the materials1040, 1042, 1044, 1046 include varying sealed locations where two layersof the film for each of the materials are connected together. Thelocation, size, geometry, and the like of the sealed locations definesthe pillow pattern when the material 1040, 1042, 1044, 1046 is inflatedby the inflation and sealing assembly. The patterns shown in FIGS. 1A-1Dare meant as exemplary only and many other patterns may be used.

The control system 1000 is configured to automatically adjust componentsof the inflation and sealing assembly, as well as provide output to auser indicating which components should be adjusted. In someembodiments, the control system 1000 is able to adjust the settings ofcertain components that are not typically adjustable in conventionalinflation and sealing machines. For example, the control system 1000 canadjust one or more parameters corresponding to the brake mechanism 137of the spindle 136, which allows the friction applied to the roll ofmaterial to be adjusted. Additionally, the control system 1000 canadjust the ramp up and down profiles for a plurality of motors of theinflation and sealing assembly, which allows the motors and variouscomponents to be customized to the recipe of the material beingprocessed, as well as to the operating conditions of the inflation andsealing mechanism.

A method of operating the inflation and sealing assembly will now bediscussed in further detail. FIG. 15 is a flow chart illustrating amethod of operating the inflation and sealing assembly. With referenceto FIG. 15, the method 2000 may be begin with operation 2002 and thecontrol system 1000 may determine the type of material loaded onto thespindle 136. In some embodiments, one of the sensors 1016 of the controlsystem 1000 may sense or receive data from the material to determine thetype of material. In a first example, the sensor 1016 may scan a barcodeembedded, attached, or otherwise connected to the roll of material andthe processor 1002 may analyze the barcode to determine the type ofmaterial and optionally the settings of one or more components of theinflation and sealing assembly. In a second example, the sensor 1016 mayinclude a RFID receiver and may receive a RFID identifier attached theroll of material or packaging and the processor 1002 may use the RFIDidentifier to determine information about the material. In a thirdexample, the sensor 1016 may be a camera and capture an image of thematerial and/or the material label (e.g., packaging) and the processor1002 will analyze the picture to determine the material. In a forthexample, the control system 1000 may receive input from a user. In thisexample, the user may directly input the material data into the controlsystem 1002 via the input/output interface 1012, e.g., via a keyboard,mouse selecting an icon, or the like. In a fifth example, the controlsystem 1000 may receive material data from another computing device suchas through a network, server, or the like. The above list of examples isnot meant as exhaustive, but merely illustrative. Many other embodimentsare envisioned.

Once the material has been determined, the method 2000 may proceed tooperation 2004. In operation 2004 one or more parameters of theinflatable cushions or pillows may be determined. For example, thematerial may have a predetermined inflation design where select areas ofthe material are sealed together or open to define inflatable pocketsthat expand when filled with air. In some examples, the pillowparameters may be predetermined based on the type of material, i.e., thepillow parameters may be encompassed within a description of thematerial loaded onto the spindle 136. After the pillow parameters havebeen determined, which may be encompassed with operation 2002, themethod 2000 may proceed to operation 2006.

In operation 2006 the control system 1000 determines a recipe for usingthe inflation and sealing assembly to create the packaging materialusing the raw material on the spindle 136. The control system 1000 usesthe material information and/or pillow parameters from operations 2002,2004, respectively, to adjust or modify one or more components on theinflation and sealing assembly. For example, the processor 1002 may pulla recipe for the select material on the spindle 136 from the memorycomponent 1006 once the material or other identifier has beendetermined. In some embodiments, the recipe may be directly input to thecontrol system 1000, such as through the input/output interface, throughthe display 1004 (e.g., a user selecting an icon corresponding to thematerial), or the recipe may be tagged or otherwise connected to thematerial 1009 itself (e.g., embedded as a code, text, or the like).

The recipe includes data such as the speed of one or more motors (e.g.,blower motor, drum motor, brake mechanism motor), the temperature of theheating element 177, the air speed or other settings of the blower 1013,inflation rate, ramp up speed for the motors, heater ramp up temperatureand profile, the initial tension setting for the brake mechanism 137, atension setting at a “stop” position for the brake mechanism 137, fillheight of the pillows, a blower start up temperature of the blower 1013at start up, an initial temperature for the sealing drum 166/heatingelement 177, a motor stop delay time, ramp up/down profiles for one ormore components (e.g., sealing drum 166, blower 1013, brake mechanism137, etc.), spacing chambers for the materials, fill volume, widthand/or length of the material, coatings present on the material (e.g.,blocking prevention coatings). In other words, the recipe includessettings or operating profiles for a plurality of components for theinflation and sealing assembly. Additionally, the recipe data mayinclude parameters for start-up, normal operating, and stopping. Forexample, the parameters of each component may need to be varied based onthe components warm up time, operating parameters and slow down time.The number of components adjusted may be varied based on the material,the type of inflation and sealing assembly, operation speed, operationtemperature, and so on. As such the components adjusted listed hereinare meant as illustrative only.

In another embodiment, the processor 1002 may analyze the material andpillow parameters to determine the recipe. In other words, using dataabout the material and the pillow parameters the processor 1002 maycreate the recipe either in real time or substantially in real time. Forexample, the processor 1002 may determine certain characteristics orsettings based on the material information, i.e., the material has athickness of X inches and therefor will set the temperature in theheating and sealing element that will heat through the thickness. In yetanother embodiment, the processor 1002 may pull the recipe from thememory component 1006, a network, server, material manufacture'swebsite, or substantially any other computing device. That is, therecipe may be stored within and/or accessed by the control system 1000.

To assist in understanding the present disclosure, the followingexamples are included to illustrate example recipes that can be used bythe control system 1000. The examples described herein should not, ofcourse, be construed as specifically limiting the disclosure and suchvariations of the disclosure, now known or later developed, which wouldbe within the purview of one skilled in the art are considered to fallwithin the scope of the disclosure as described herein and hereinafterclaimed.

In the recipes below the names used refer to the following parameters.DESC is the material identification (e.g., trade name or description).SPEED is the speed setting for the sealing drum 166 from 1-100 (e.g., aspeed of 75 is 75% of the top speed). BLWER is the blower or air settingas a percentage of maximum air flow. TEMP is the temperature of theheating element or other seal setting in the recipes in Fahrenheit.BRAKE_START is the steady state tension setting for the brake mechanismand is a percentage of the total braking force or torque. As describedabove, in some instances the braking mechanism 137 may be a motor thatrotates in the opposite direction from the drum motor. In theseexamples, the braking force may be a percentage of motor power (e.g.,1-100%) that is applied to the braking mechanism 137. In examples wherethe braking mechanism is a frictional element, the braking force may bedetermined as a position (farthest to closest) to the roll of materialor by another characteristics. BRAKE_END is the braking tension of thebraking mechanism during “stop,” and similarly to BRAKE_START may be apercentage of the motor speed or another braking characteristicdepending on the type of braking mechanism used. BSTRT is the blowerstart up temperature in Fahrenheit. MSTRT is the motor start uptemperature in Fahrenheit. MSTOP is the motor stop delay inmilliseconds.

MUP is the motor ramp up profile, MDOWN is the motor ramp down profile,BUP is the blower ramp up profile, BDOWN is the blower ramp downprofile, and BKEND is the brake mechanism ramp up profile at stop. Theramp up and ramp down profiles are profiles of the various components ofthe inflation and sealing assembly as it turns on and as it turns off.For example, when a motor is first activated it may need to rotate itsdrive shaft at a lower speed for a select period of time before thespeed can be increased to maximum or near maximum to avoid damaging themachine or the other components positioned or connected to the machine.This is because some motors may have different rotational parameters asthey are powered up as compared to when they have been running for aselect period of time. By using a ramp up time the control system cangradually increase the power to the motor to full speed. Similarly, themotors may be damaged if they suddenly stop rotating after they havebeen rotating at full speed (or close to full speed). Accordingly, someof the recipes may include a ramp down profile that slowly decreases thepower provided to the motor to gradually reduce the speed until themotor can be safely stopped completely. The ramp up and ramp down timesand speeds may be determined based not only on the mechanicalcomponents, but also the material and recipe properties. For example, ifthe maximum speed desired for a particular material is slower than atypical operating speed, the ramp up time for the motor may beincreased. As another example, the weight of the material roll mayimpact the ramp up and/or ramp down profile, e.g., a heavier materialmay require a longer and slower ramp up process as compared to a lightermaterial.

In the recipes below the ramp up and ramp down profiles are listed as afunction of time and the motor speed percentage. For example withreference to the first example recipe and MUP, at time 0 the motor speedis 0% of max, at 1300 ms the motor speed is 50% of max, at 2000 ms themotor speed is 80% of max, at 2800 ms the motor speed is 95% of max, andat 3200 ms the motor speed is 100%. In this example the motor ramp upprofile takes about 3200 ms for the motor to reach full speed. Withreference to the MDOWN or motor ramp down profile in this recipe theprofile takes only 301 ms to ramp down, i.e., the motor ramp downprofile is much faster than the motor ramp up profile. By changing theramp up and ramp down profiles of the inflation and sealing assemblycomponents based on the material being inflated and sealed, the assemblymay operate safer and may have a reduced chance of damage to components,such as the motors, as they may be adequately ramped up/down beforereaching maximum speed and stopped positions.

It should be noted that the above units and parameters are illustrativeonly and may be varied based on the type of machine, materials, and soon. For example, in the recipe examples provided below a plurality ofthe settings are selected as a percentage of the maximum level for theselect component. However, in other examples, the settings may beselected as an absolute value (the temperature settings in the recipeexamples are set as these values). Alternatively or additionally therecipes may include ranges of the settings, e.g., 50-60% of maximumspeed and the control system 1000 may select the appropriate settingbased on the current operating conditions.

A first example of a recipe that may be used to inflate and sealmaterial 1046 illustrated in FIG. 1D is provided below.

-   -   DESC=Material 1    -   SPEED=85    -   BLWER=55    -   TEMP=320    -   BRAKE_START=5    -   BRAKE_END=100    -   BSTRT=295    -   MSTRT=290    -   MSTOP=400    -   MUP=0, 0, 1300, 50, 2000, 80, 2800, 95, 3200, 100,    -   MDOWN=0, 100, 100, 50, 200, 25, 300, 0, 301, 0,    -   BUP=0, 0, 500, 50, 1850, 70, 3500, 100, 3600, 100,    -   BDOWN=0, 100, 5, 50, 25, 0, 26, 0, 27, 0,    -   BKEND=0, 0, 250, 60, 300, 75, 360, 100, 600, 0,

A second recipe example is provided below. This recipe may be used toinflate and seal material 1042 shown in FIG. 1B.

-   -   DESC=Material 3    -   SPEED=65    -   BLWER=100    -   TEMP=330    -   BRAKE_START=15    -   BRAKE_END=90    -   BSTRT=300    -   MSTRT=320    -   MSTOP=400    -   MUP=0, 0, 2000, 70, 2500, 95, 2700, 100, 2800, 100,    -   MDOWN=0, 100, 150, 90, 250, 75, 300, 40, 500, 0,    -   BUP=0, 0, 1500, 80, 2000, 95, 2200, 100, 2300, 100,    -   BDOWN=0, 100, 5, 50, 25, 0, 26, 0, 27, 0,    -   BKEND=0, 0, 300, 50, 375, 80, 425, 100, 600, 0,

Using a stored recipe or otherwise accessing a recipe the control system1000 can determine the settings for one or more components of theinflation and sealing assembly. With reference against to FIG. 15, inoperation 2006, the control system 1000 may not only determine thetypical recipe for the material and pillow parameters, but may alsoadjust the recipe based on the parameters of the inflation and sealingassembly. For example, if the recipe specifies a first temperature forthe heating element 177, but the sealing drum 166 is running slower thantypical, the control system 1000 may adjust the temperature tocompensate for the slower speed. As another example, the brakingfriction applied by the braking mechanism 137 may be may be set to afirst level but if the roll of material has a larger or smaller diameterthan typical or larger than the diameter used to create the recipe, thecontrol system 1000 may dynamically adjust the braking friction tocompensate for this change. Other changes to parameters of the inflationand sealing assembly based on changes to one or more parameters based oninterrelated functionality will be discussed in more detail below withrespect to 15.

It should be noted that in some embodiments, the inflation and sealingassembly may not identify any material parameters or pillowcharacteristics. In these embodiments, the control system 1000 maydetermine the recipe by using the identifier 1010 on the material 1009itself or the recipe may be accessed by using a lookup table or otherresource based on an arbitrary material name (e.g., trade name) or thelike. In these embodiments, the control system 1000 may access therecipe as it is stored in memory, over a network, or the like withouthaving to determine any of the parameters of the material itself.

With continued reference to FIG. 15, once the recipe has been determinedor otherwise accessed, the method 2000 may proceed to operation 2008. Inoperation 2008 the various components of the inflation and sealingassembly are adjusted based on the recipe. In other words, thecomponents are set at the desired settings based on the data of therecipe. In one embodiment, each of the components may be adjusted by thecontrol system 1000 automatically. However, in other embodiments, selectcomponents may need to be adjusted by a user. In these embodiments, thedisplay 1004 or other output element provides output to a user to othercomputing device to indicate the parameters that need to be manuallymodified. For example, the display 1004 may display a picture or icon ofthe component with an indication of the setting that needs to beadjusted.

In embodiments where the components of the inflation and sealingassembly can be adjusted by the control system 1000, the control system1000 will provide instructions for the various components regarding thesetting and can then confirm that the components are set at the desiredlevels.

After operation 2008, the method 2000 may proceed to operation 2010. Inoperation 2010 the inflation and sealing assembly is activated andoperates. In particular, the assembly begins to run and the material isfed from the spindle through the assembly to create the packagingmaterial. While the inflation and sealing assembly is operating, themethod 2000 may proceed to optional operation 2012. In operation 2012the control system 1000 may receive feedback regarding the functionalityof the inflation and sealing assembly and/or various components of theinflation and sealing assembly. For example, one or more sensors maydetect the real time functioning of the machine or components, such asthe temperature of the heat/sealing element, the speed of the motor, thebraking friction being applied, and so on. This operation 2012 allowsthe control system 1000 to receive real time or substantially real timefeedback regarding the assembly.

After operation 2012, the method 2000 may proceed to operation 2014. Inoperation 2014 the control system 1000 determines whether any componentsor parameters of the inflation and sealing assembly should be adjusted.For example, using feedback from operation 2012 (e.g., sensor readingswhile the machine is operating), the control system 1000 may determinethat one or more components need to be adjusted. This feature allows thecontrol system 1000 to dynamically adjust the inflation and sealingassembly during operation.

If in operation 2014 one or more components should be adjusted, themethod 2000 proceeds to operation 2016. In operation 2016, the controlsystem 1000 modifies the parameter or component. Operation 2016 may besubstantially similar to operation 2008, but may be adjusted based notonly the recipe and material, but also on the real time operation of thesealing and inflation machine itself. For example, if the selectcomponent is not running as programmed to do or based on the othercomponents of the machine should be modified that component may bemodified accordingly. As a specific example, the motor is not operatingat the programmed speed, such as due to a malfunction or error, theheating element may be turned down to account for the slower speed).

If in operation 2014 components did not need to be adjusted or afteroperation 2016 and the components have been adjusted, the method 2000may proceed to operation 2018. In operation 2018 the control system 1000determines whether another roll of material is to be loaded onto theinflation and sealing assembly. If another roll is to be loaded, themethod 2000 returns to operation 2002. However, if another roll is notto be loaded, the method 2000 proceeds to an end state.

Using the method 2000 and the control system 1000, the inflation andsealing assembly can adjust the parameters of the assembly to accountnot only for the material to be inflated and sealed, but also on theoperating conditions of the assembly itself. This allows the inflationand sealing assembly to more quickly create packaging material, as wellas help to avoid errors or other issues that could arise due tomalfunctions in the machines or deviations from expected performance ofthe various components of the inflation and sealing assembly.

In some embodiments the control system 1000 may set and/or adjust one ormore parameters based on the interdependencies or correlations betweentwo or more parameters. For example, in some instances modifying a firstparameter can affect a second parameter and the inflation and sealingassembly may not function as desired if the second parameter is not alsoadjusted. Parameters may be related by a 1:1 relationship, e.g., as oneincreases the other should be increased by the same amount, by apercentage relationship, e.g., as one parameter increases by 20% thesecond parameter should increase by 5%, by an inverse relationship,e.g., as one parameter increases the other decreases, and so on. Therelated parameters and their relationships may be varied based on thegeometry and configuration of the inflation and sealing assembly, thetype of material, the operating speed, operating environment, and othercharacteristics. As such, the parameters and relationships listed hereinare meant as illustrative only and may change.

A method for varying one or more parameters based on changes to one ormore other parameters will now be discussed in more detail. FIG. 16 is aflow chart illustrating a method for adjusting parameters of theinflation and sealing assembly. With reference to FIG. 16, the method3000 may begin with operation 3002. In operation 3002 a first parameteris changed on the inflation and sealing assembly. The parameter may bechanged due to the input of a recipe based on a material being loadedonto the assembly, may be changed by a user, or may be otherwise varied.The parameter may be changed automatically or manually. Once theparameter has changed, the method 3000 may proceed to operation 3004. Inoperation 3004, the control system 1000 determines whether there is aninterdependent parameter. In other words, the control system 1000analyzes whether there is another parameter functionally related to thechanged parameter. In this manner the controls system 1000 determineswhether there is any relationship between the changed parameter andother parameters of the inflation and sealing assembly.

If in operation 3004 there is a related parameter the method 3000 mayproceed to operation 3010. In operation 3010 the control system 1000evaluates the related parameter to determine if it should also beadjusted. For example, the control system 1000 may analyze the amount ofchange to the first parameter to determine whether the range issufficient to warrant a change to the second parameter. In this example,certain adjustments to the first parameter may be sufficiently smallthat the second parameter may not need to be adjusted, although it isfunctionally related to the first parameter.

If in operation 3010 the second parameter should be adjusted, the method3000 may proceed to operation 3014. In operation 3014 the relatedparameter is adjusted. In some embodiments, the control system 1000 mayautomatically change the related parameter. As one example, the controlsystem 1000 can vary a signal provided to a component that will changethe parameter, such as the speed of the motor or the temperature of theheating element. In other embodiments, the control system 1000 mayprovide output to indicate to a user that the parameter needs to beadjusted. As an example, the control system 1000 may cause an alert tobe displayed on the display 1004. The alert may indicate the parameterto be changed and the change amount or new setting. In theseembodiments, the parameter may be adjusted manually by a user.

After the related parameter has been changed, the method 3000 mayproceed to operation 3016. In operation 3016 the control system 1000determines whether there are any other related parameters. For example,often one parameter may be functionally related to two or moreparameters and thus as one parameter is changed multiple otherparameters may also need to be changed. As another example, a firstparameter may be related to a second parameter and the second parametermay be related to a third parameter. In this example, as the secondparameter is adjusted based on the modifications to the first parameter,the third parameter may also need to be adjusted. If there are otherrelated parameters the method 3000 may return to operation 3010.However, if there are no other related parameters, the method 3000 mayproceed to an end state 3018.

With continued reference to FIG. 16, if in operation 3004 there are norelated parameters or if in operation 3010 the related parameters arenot to be adjusted, the method 3000 may proceed to operation 3006. Inoperation 3006 the control system 1000 may determine whether there areother changes to the system that should be evaluated. For example, ifone or more parameters or components is not operating as desired, if thematerial changes, and/or if the operating environment changes, thecontrol system 1000 want to reevaluate whether other parameters shouldbe changed.

If there have been other changes to the system, the method 3000 mayproceed to operation 3008. In operation 3008 the control system 1000determines whether any parameters should be modified based on thesechanges. If so, the method 3000 returns to operation 3002. However, ifthe parameter does not need to be changed despite changes to the systemor if in operation 3006 there have not been other changes to the system,the method 300 proceeds to the end state 3018.

Using the method 3000 the inflation and sealing assembly can dynamicallyadjust to conditions during operation, as well as adjust parameters tocompensate for adjustment in other parameters. For example, in someembodiments the inflation and sealing assembly may implement recipesthat are stored either in the memory component 1006, other computingdevice, or identified by the material itself (e.g., via the identifier1010) and the recipes may include settings for certain components butmay not include settings for others. Using the method 3000 the controlsystem 1000 can determine the changes to all parameters, even if thoseparameters are not directly part of the recipe.

Any and all references specifically identified in the specification ofthe present application are expressly incorporated herein in theirentirety by reference thereto. The term “about,” as used herein, shouldgenerally be understood to refer to both the corresponding number and arange of numbers. Moreover, all numerical ranges herein should beunderstood to include each whole integer within the range. The contentof U.S. patent application Ser. No. 13/844,741 is hereby incorporated byreference in its entirety.

While illustrative embodiments of the invention are disclosed herein, itwill be appreciated that numerous modifications and other embodimentsmay be devised by those skilled in the art. For example, the featuresfor the various embodiments can be used in other embodiments. Therefore,it will be understood that the appended claims are intended to cover allsuch modifications and embodiments that come within the spirit and scopeof the present invention.

What is claimed is:
 1. A method for modifying one or more parameters ofa film inflation and sealing machine, comprising: providing a deviceconfigured to inflate and seal film to make packaging material;providing a supply of film material; identifying a configuration of thesupply material; and receiving a selection of a prestored recipeaccording to the configuration of the supply material; wherein therecipe determines one or more operating parameters of the machine. 2.The method of claim 1, wherein the configuration of the supply materialcomprises one or more characteristics of the supply material.
 3. Themethod of claim 1, wherein the one or more characteristics includethickness and one or more dimensions.
 4. The method of claim 2, whereinidentifying a configuration of the supply material comprises detectingthe one or more characteristics of the supply material by a sensor. 5.The method of claim 1, wherein identifying a configuration of the supplymaterial comprises detecting by a sensor, material data connected to orembedded within the supply material.
 6. The method of claim 5, whereinthe sensor is a radio frequency identification sensor.
 7. The method ofclaim 5, wherein the material data is stored as a barcode or a quickresponse code connected to the material.
 8. A method for modifying oneor more parameters of an inflation and sealing assembly comprising:selecting a predetermined recipe from a plurality of recipes; andconfiguring the inflation and sealing assembly to operate based on thepredetermined recipe; wherein the predetermined recipe includes settingsfor a plurality of components of the inflation and sealing assembly. 9.The method of claim 8, further comprising operating the inflation andsealing assembly using the settings based on the predetermined recipe.10. The method of claim 8, wherein selecting the predetermined recipecomprises: displaying one or more icons on a display corresponding toone or more materials; and receiving a user input identifying a firsticon of the one or more icons.
 11. The method of claim 10, wherein theuser input is received through the display or through an input device.12. The method of claim 8, wherein selecting the predetermined recipecomprises: receiving a material input corresponding to a first material;and retrieving from a memory component a first recipe corresponding tothe first material.
 13. The method of claim 12, wherein receiving amaterial input comprises: scanning the first material by a radiofrequency identification sensor; and retrieving material data from aradio frequency identification tag connected to the first material. 14.The method of claim 13, wherein receiving a material input comprises:detecting by a sensor one or more material characteristics of the firstmaterial.
 15. The method of claim 8, wherein selecting the predeterminedrecipe comprises: receiving a material input corresponding to a firstmaterial; and retrieving from a computing device a first recipecorresponding to the first material.
 16. A method for modifying one ormore parameters of a machine, comprising: modifying a first parameterbased on at least one of a material, a material size, a desiredinflation rate, an inflation pocket geometry, or a feed speed; analyzinga second parameter to determine if the second parameter is functionallyrelated to the first parameter; if the second parameter is functionallyrelated to the first parameter, adjusting the second parameter tocorrespond to the modification to the first parameter; and if the secondparameter is not functionally related to the first parameter notadjusting the second parameter.
 17. The method of claim 16, wherein aprocessing element analyzes the second parameter to determine if thesecond parameter is functionally related to the first parameter.
 18. Themethod of claim 16, wherein if the second parameter is functionallyrelated to the first parameter further comprising analyzing a firstmodification to the first parameter to determine a second modificationto the second parameter, wherein the second modification is related tothe first modification by a predetermined function.
 19. The method ofclaim 16, further comprising: receiving material data comprising atleast one of the material, the material size, the desired inflationrate, the inflation pocket geometry, or the feed speed; and analyzingthe material data to determine a first modification to the firstparameter.
 20. The method of claim 19, wherein a processing elementreceives the material data from an input/output component in electricalcommunication therewith.
 21. The method of claim 20, wherein theinput/output component is at least one of a bar code scanner, a radiofrequency identifier, a keyboard, a display screen, or a mouse.
 22. Amethod for creating packaging materials, comprising: selecting at leastone material parameter of a packaging material; determining a settingfor a first machine parameter based on the at least one materialparameter; adjusting the first machine parameter based on the setting;determining if a second machine parameter should be adjusted based onthe setting for the first machine parameter; and adjusting the secondmachine parameter based on the determination.
 23. The method of claim22, wherein the second machine parameter is adjusted in a related mannerto the setting of the first parameter.
 24. The method of claim 22,wherein the first parameter is a drum motor and the second parameter isa brake mechanism.
 25. An inflation and sealing assembly, comprising: aspindle for receiving a supply of material; a brake mechanism operablyconnected to the spindle, wherein the brake mechanism selectivelyapplies a frictional force to the supply of material; and a controlsystem in communication with the brake mechanism, the control systemselectively varying the frictional force applied by the brake mechanism.26. The inflation and sealing assembly of claim 25, wherein the brakemechanism is a motorized brake.
 27. The inflation and sealing assemblyof claim 25, wherein the control system varies the frictional forcebased on a recipe corresponding to the material.
 28. A method foroperating an inflation and sealing assembly, comprising: selecting atleast one material parameter of a packaging material; and determining aramp up profile for at least one component of the inflation and sealingassembly based on the at least one material parameter.
 29. The method ofclaim 28, further comprising determining a ramp down profile for the atleast one component.
 30. The method of claim 28, wherein the at leastone component is at least one of a drum motor or a braking mechanism.31. A web inflation device comprising: an inflation assembly configuredfor insertion between first and second overlapping film plies of a webof material the inflation assembly having a fluid conduit configured fordirecting a fluid in between the plies to inflate the web; a sealingmechanism to seal the plies together to seal the fluid therein; and asupport element that supports an uninflated portion of the web ofmaterial; and a controller in electrical communication with theinflation assembly and the support element, wherein the controller isconfigured to receive an identification corresponding to a configurationof the supply material; select a prestored recipe according to theconfiguration of the supply material; and vary one or more operatingparameters of the inflation assembly or sealing mechanism.